Equipment platform

ABSTRACT

Improved equipment bases and methods for making and using same are disclosed herein. The equipment base can include a first coated substrate including a first part having a first thickness sized to provide the load-bearing support for the equipment, a first elastomer coating the first part, a second coated substrate positioned adjacent to the first coated substrate, the second coated substrate including a second part having a second thickness sized to provide the load-bearing support for the equipment, and a second elastomer coating the second part. A first seam can be formed between the first and second coated substrates to allow for moisture to pass between the first and second coated substrates so that moisture is allowed to seep away from the bottom of the equipment.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/697,427 filed Nov. 27, 2019, which is a continuation of U.S. patentapplication Ser. No. 15/614,720 filed Jun. 6, 2017, now issued as U.S.patent Ser. No. 10,495,172. Each of the aforementionedapplications/patents is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a structural element that providesload bearing support. In particular, the present disclosure provides anencapsulated material that can serve as a load bearing support forvarious types and sizes of industrial equipment.

BACKGROUND

There are several types of equipment used on or near well sites,compressor stations, refineries, and chemical plants such ascompressors, treater units, cooling units, heaters, pumps, and the like.

Oftentimes, supports or foundations for such equipment involve the useof gravel or dirt pads built specifically for each type of equipment.Inclement weather can wash out these gravel and dirt pads, causing theequipment to become unstable. Moreover, building pads specifically foreach type of equipment consumes time for pre-planning and constructing apad suitable for each type of equipment. It can take several days toplan and construct these pads.

A need exists for an improved equipment base that can withstandinclement weather conditions. There is also a need for an equipment basethat provides for a more time-effective and cost-effective means of theshipping, transporting, and installation into customer sites.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings facilitate an understanding of the variousexemplary embodiments.

FIG. 1 is a perspective view of a system having an equipment basesupporting an equipment unit, according to an exemplary embodiment.

FIG. 2 is a top view of the equipment base of FIG. 1.

FIG. 3 is a side view of the equipment base of FIG. 1.

FIG. 4 is side view of another equipment base, according to an exemplaryembodiment.

FIG. 5 is a perspective view of another equipment base, according to anexemplary embodiment.

FIG. 6 is a perspective view of the equipment base of FIG. 5.

FIG. 7 is a top view of a segment of the equipment base of FIG. 5.

FIG. 8 is a top view of another segment of the equipment base of FIG. 5.

FIG. 9 is a top view of a key member of the equipment base of FIG. 5.

FIG. 10 is a top view of a side member of the equipment base of FIG. 5.

DETAILED DESCRIPTION

In an exemplary embodiment, as illustrated in FIG. 1, a system isgenerally referred to by the reference numeral 100 and includes anequipment base 102 that extends over the ground surface. An equipmentunit 104 having a bottom or lowermost portion 105 is shown positioned ontop of the equipment base 102 so that the equipment base 102 supportsthe equipment unit 104, preventing the lowermost portion 105 of theequipment unit 104 from contacting the ground surface. The equipmentunit 104 can be or include any one or more devices, systems,apparatuses, including for example, an HVAC unit, a heat exchanger, acompressor, a pump, a mixing vessel, a reactor vessel, a storage tank, asurge drum, an engine, and the like and any combination thereof.

FIG. 2 is a top view of the equipment base 102 of FIG. 1. The equipmentbase 102 can be a single piece, or segment, or can include two or moresegments. As shown in FIG. 2, the equipment base 102 contains a firstsegment 106, a second segment 108, and a third segment 110. The segments106, 108, 110 can have any suitable dimensions. As shown in FIG. 2, thesegments 106, 108, 110 can each have a length y and a width (x₁, x₂, orx₃). The length y and width x₁, x₂, or x₃ can vary to any suitablemeasurements depending on the equipment unit or units to be supported.In one or more exemplary embodiments, x₁, x₂, and x₃ can beindependently from about 10 cm to about 5 m, such as from about 25 cm toabout 3 m, such as from about 50 cm to about 2 m, such as about 1 m andy can be from about 10 cm to about 10 m, such as from about 25 cm toabout 5 m, such as from about 50 cm to about 3 m, such as from about 1 mto about 2 m.

The segments 106, 108, 110 can be or include any suitable substrate. Asused herein, the term “suitable substrate” is used synonymously with“substrate” and is meant to include without limitation, concrete, metal,polymeric solids, polymeric foams, such as expanded polystyrene (EPS)and expanded polyurethane, wood, paper fiber, fiberglass, fiber board,and gravel or any other substrate appropriate for the adhesion of anelastomeric coating, such as a polyurea elastomer coating. In one ormore embodiments, a substrate includes one or more foam materials suchas EPS, polyisocyanurate foams, polyurethane foam, polyvinyl chloridefoam, polyimide foam, silicone foam, or microcellular foam or anysuitable combinations thereof. The foam material can have any suitabledensity. For example, the foam material can have a density of about 0.5pounds per square foot (lb/ft³) to about 8 lb/ft³ or more, such as fromabout 1 lb/ft³ to about 5 lb/ft³, such as from about 1.5 lb/ft³ to about3 lb/ft³, such as from about 2 lb/ft³ to about 2.5 lb/ft³. In one ormore exemplary embodiments, the foam material has a density from about1.5 lb/ft³ to about 2.5 lb/ft³. The foam material can be substantiallynon-degradable or substantially degradable. In one or more exemplaryembodiments, the foam material is biodegradable.

The substrate can have any suitable thickness sized to support anysuitable equipment. In one or more exemplary embodiments, the substratecan have a thickness of from about 0.5 inch to about 12 inches or more,such as from about 1 inch to about 8 inches, such as from about 2 inchesto about 6 inches, such as from about 3 inches to about 5 inches, forexample about 4 inches. For example, a piece of equipment weighingapproximately 50,000 pounds can be supported by EPS having a foamdensity of 2 pounds per cubic foot of foam weight, ranging from about 3to about 12 inches in thickness.

The segments 106, 108, 110 can also include an elastomeric outer coatingor layer. In one or more exemplary embodiments, the segments 106, 108,110 are each encapsulated with the elastomeric layer. The elastomericlayer can be or include any polymeric material that can both create afluid impermeable barrier layer and adhere directly to and/or at leastpartially penetrate the foam material of the segments 106, 108, 110. Inone or more embodiments, the polymeric material can be or includepolyurea. The elastomeric coating can have any suitable thickness. Inone or more exemplary embodiments, the elastomeric coating of the liner104 can have a thickness about 5 mil, about 10 mil, about 15 mil, 20mil, about 30 mil, about 40 mil to about 50 mil or more.

The segments 106, 108, 110 can also have any suitable thickness sized tosupport any suitable equipment. In one or more exemplary embodiments,the segments 106, 108, 110 can have a thickness of from about 0.5 inchto about 12 inches, such as from about 1 inch to about 8 inches, such asfrom about 2 inches to about 6 inches, such as from about 3 inches toabout 5 inches, for example 4 inches. For example, a piece of equipmentweighing approximately 50,000 pounds can be supported by segments 106,108, 110 having a thickness from about 3 inches to about 12 inches.

The segments 106, 108, 110 can form one or more seams 120 (two areshown) when positioned adjacent one another to form the equipment base102. These seams can allow for moisture to pass between the segments andaway from the equipment 104 and its lowermost portion 105, therebypreventing corrosion of the lowermost portion 105.

FIGS. 3 and 4 illustrate side views of the equipment bases and a coupleof corresponding seams possible with the present disclosure. Straightseams depicted in FIG. 3 allow for any moisture from rainwater, forexample, to pass through so as to prevent corrosion of the equipmentfrom standing water effects. Interlocking seams seen in FIG. 4 alsoallow for moisture to seep away from the bottom of the equipment butalso allow for another embodiment in which to piece or hold together thesubstrates. In one or more exemplary embodiments (not shown), thesegments 106, 108, 110 can contain protrusions and correspondingrecesses to form interlocking seams connecting adjacent segmentstogether. In one or more exemplary embodiments (not shown), a strap witha cam buckle can be used to secure the segments 106, 108, 110 around theouter periphery of the edges and hold the pieces together until thepressure from the weight of the equipment is applied.

An exemplary method for constructing the equipment base 100 can includespraying an elastomeric coating onto the substrates to form the segments106, 108, 110. The segments 106, 108, 110 can then be positionedadjacent to one another to form the equipment base 100.

FIG. 5 is a perspective view of another equipment base 200. Theequipment base 500 can include any number of segments. Four segments areshown in FIG. 5 (202, 204, 206, 208) though it is contemplated hereinthat the equipment base 200 can include 2, 6, 8, or 10 or more segments.Adjacent segments, for example, 202 and 204, can be adjoined to eachother by a key member 210. Key member(s) 210 can have the samecomposition and thickness as the segments 202, 204, 206, 208. In one ormore exemplary embodiments, any adjacent segments can also be adjoinedto one another by any suitable means, for example, with adhesives,fasteners, nails, screws, bolts, and sealants and the like. Theequipment base 200 can include one or more side members 212 for fillingany gaps (see FIGS. 7 and 8) in the exposed sides of the equipment base200. Like key member 210, the side member 212 can have the samecomposition and thickness as the segments 202, 204, 206, 208. FIG. 6 isa perspective view of the equipment base of FIG. 5.

The segments 202, 204, 206, 208, the key member 210 and the side member212, can have the same dimensions, compositions and thicknesses asdiscussed above for segments 106, 108, 110. FIG. 7 is a top view ofsegment 202 of equipment base 200. Segment 202 can include two sides 302a, 302 b and two ends 303 a, 303 b. Segment 202 can include a length Lmeasured along a side 302 a, 302 b from about 10 cm to about 10 m, suchas from about 25 cm to about 5 m, such as from about 50 cm to about 3 m,such as from about 1 m to about 2 m and a width W measured along an end303 a, 303 b from about 10 cm to about 5 m, such as from about 25 cm toabout 3 m, such as from about 50 cm to about 2 m, for example about 1 m.Segment 202 can include one or more recesses 304 (four are shown). Therecesses 304 can include an inner arcuate portion 320 and an outerarcuate portion 322. A linear segment 321 can be disposed between theinner arcuate portion and the outer arcuate portion. The inner arcuateportion 320 can have an inner radius of curvature R1 and the outerarcuate portion 322 can have an outer radius of curvature R2. The innerradius of curvature R1 can be from about 0.75 inch to about 1.5 inch,such as from about 1 inch to about 1.35 inch, such as from about 1.25inch to about 1.3 inch. The outer radius of curvature R2 can be fromabout 0.25 inch to about 1 inch, such as from about 0.5 inch to about0.9 inch, such as from about 0.7 inch to about 0.8 inch.

FIG. 8 is a top view of segment 206 of equipment base 200. As shown,segment 206 can have a different size and shape than segment 202, thoughit is contemplated herein that segment 206 can be the same size andshape as segment 202. Segment 206 can include two sides 307 a, 307 b andtwo ends 306 a, 306 b. Segment 206 can include a length L measured alonga side 307 a, 307 b from about 10 cm to about 10 m, such as from about25 cm to about 5 m, such as from about 50 cm to about 3 m, such as fromabout 1 m to about 2 m and a width W measured along an end 303 a, 303 bfrom about 10 cm to about 5 m, such as from about 25 cm to about 3 m,such as from about 50 cm to about 2 m, for example about 1 m. Segment206 can also include the one or more recesses 304 discussed above (fourare shown).

FIG. 9 is a top view of key member 210 of equipment base 200. The keymember 210 can have one or more protruding portions 309 (four are shown)and one or more recessed portions 308 (two are shown). The protrudingportion 309 can have an arcuate shape adapted to fit within the innerarcuate portion 320. The protruding portion 309 can have a radius ofcurvature R3 of from about 0.25 inch to about 1 inch, such as from about0.5 inch to about 0.9 inch, such as from about 0.7 inch to about 0.8inch.

FIG. 10 is a top view of side member 212 equipment base 200. The sidemember 212 can have one or more protruding portions 310 (two are shown).The protruding portion 310 can have an arcuate shape adapted to fitwithin the inner arcuate portion 320. The protruding portion 310 canhave a radius of curvature R3 of from about 0.25 inch to about 1 inch,such as from about 0.5 inch to about 0.9 inch, such as from about 0.7inch to about 0.8 inch.

An exemplary method for constructing the equipment base 200 can includespraying an elastomeric coating onto the substrates, or cores, ofsegments (such as segments 106, 108, 110, 202, 204, 206, 208), keymembers (such as key members 210) and side members (such as side members212) so that the segments, the key members and/or the side members areeach independently coated or encapsulated with the elastomeric coating.The coated segments (such as segments 106, 108, 110, 202, 204, 206, 208)can be connected to each other via key members 210 as shown in FIGS. 5and 6. To complete the equipment base 200, side members 212 can beplaced into any exposed recess in the outward facing side walls of thesegments 202, 204, 206, 208 as shown in FIGS. 5 and 6.

The coated segments (such as segments 202, 204, 206, 208), the keymembers 210 and the side members 212 can form one or more seams whenpositioned adjacent one another to form the equipment base 200. Theseseams can allow for moisture to pass between the segments and away fromany equipment 104 supported by the equipment base 200. In one or moreexemplary embodiments, the seams can be at least partially filled withadhesives, caulking material, the elastomeric coating or any other typeof suitable filler material.

Though particular shapes of equipment bases, its segments and othercomponent parts are disclosed herein, the equipment base can include anysuitable configuration, size, and shape. For example, the equipment basecan have a triangular, square, rectangular, circular, oval, hexagonal,or octagonal footprint and can be from about 1 foot to about 50 feet ormore in its largest dimension, such as from about 2 feet to about 20feet, such as from about 3 feet to about 12 feet, such as from about 4feet to about 8 feet, for example about 6 feet. In several exemplaryembodiments, the equipment base has a square or rectangular footprint,and ranges from about 1 foot to about 20 feet in length, and from about1 foot to about 20 feet in width.

The equipment bases disclosed herein can provide improved support forseveral types of equipment. The equipment can be or include any one ormore devices, systems, apparatuses, including for example, an HVAC unit,a heat exchanger, a compressor, a pump, a mixing vessel, a reactorvessel, a storage tank, a surge drum, an engine, and the like and anycombination thereof.

During operation, the equipment can produce vibrational forces that canaffect the support of the equipment. An equipment base of the presentdisclosure can distribute vibrational forces produced by the equipmentto enable vibration dampening. In one or more exemplary embodiments, anequipment base of the present disclosure can be configured to dampenmovement of the equipment relative to at least one dimension. In one ormore exemplary embodiments, an equipment base of the present disclosurecan be configured to dampen the vibration of the equipment relative tothe ground.

The equipment base can have any suitable properties that enablevibration dampening when supporting the equipment. Shear modulus (G)represents a material's response to shear stress and, for the equipmentbase, can be from about 2 MPa to about 10 MPa, such as from about 4 MPato about 8 MPa, such as from about 4.5 MPa to about 6 MPa, such as fromabout 5 MPa to about 5.5 MPa, for example about 5.5 MPa. In one or moreexemplary embodiments, the shear modulus of the equipment base can beabout 5 MPa to about 5.3 MPa. A damping ratio (D) can be used to measuredecay of oscillations in material after a disturbance and, for theequipment base, can be from about 0.1% to about 5%, such as from about0.25% to about 2.5%, such as from about 0.5% to about 2%, such as fromabout 0.75% to about 1.8%, such as from about 0.9% to about 1.5%, suchas from about 1% to about 1.3%. In one or more exemplary embodiments,the damping ratio of the equipment base can be about 1.2% to about 1.8%.

During operation, certain equipment, such as heat exchangers, pipesystems, turbines, compressors, and HVAC systems can undergo extremetemperature changes that can result in thermal expansion or contraction,which can affect the support of the equipment. The seams inherent inequipment bases of the present disclosure can act as expansion joints,allowing the circumference or footprint of the equipment base to expandand/or contract depending on the temperature change occurring in theequipment, thereby preventing damage to the equipment or the equipmentbase. In one or more exemplary embodiments, a footprint of the equipmentbase can expand and contract due to any expansion or contraction of theequipment.

Referring again to FIG. 5, in one or more exemplary embodiments, a pieceof equipment (not shown) having four base legs can be positioned on topof the equipment base 200 so that the first base leg is on top of andaffixed or otherwise connected to segment 202 via one or more screws,bolts, welds, or other fastening devices. In a manner similar to that ofthe first leg, the second leg can be affixed to segment 204, the thirdleg can be affixed to segment 208, and the fourth leg can be affixed tosegment 206. During its operation, the equipment can expand via thermalexpansion causing the first, second, third, and fourth legs move apartfrom each other, causing the footprint of the equipment base to expand.

In one or more exemplary embodiments, the equipment base can be locatedon any side of, on top of, and/or below the equipment when it is desiredto insulate the equipment from heat exchange either from the bottomupwards or from the equipment downwards, or from side to side such asuse with freezers or industrial piping. The equipment base can providean effective, long lasting thermal insulation barrier. The equipmentbase can have an R-Value, measured in accordance with ASTM C518, of fromabout 2° F.ft²h/Btu to about 10° F.ft²h/Btu, such as from about 2.5°F.ft²h/Btu to about 8° F.ft²h/Btu, such as from about 3° F.ft²h/Btu toabout 6° F.ft²h/Btu, such as from about 3.5° F.ft²h/Btu to about 5°F.ft²h/Btu, for example about 4.5° F.ft²h/Btu.

In several exemplary embodiments, the elements and teachings of thevarious illustrative exemplary embodiments may be combined in whole orin part in some or all of the illustrative exemplary embodiments. Inaddition, one or more of the elements and teachings of the variousillustrative exemplary embodiments may be omitted, at least in part,and/or combined, at least in part, with one or more of the otherelements and teachings of the various illustrative embodiments.

Any spatial references such as, for example, “upper,” “lower,” “above,”“below,” “between,” “bottom,” “vertical,” “horizontal,” “angular,”“upward,” “downward,” “side-to-side,” “left-to-right,” “left,” “right,”“right-to-left,” “top-to-bottom,” “bottom-to-top,” “top,” “bottom,”“bottom-up,” “top-down,” etc., are for the purpose of illustration onlyand do not limit the specific orientation or location of the structuredescribed above.

In several exemplary embodiments, while different steps, processes, andprocedures are described as appearing as distinct acts, one or more ofthe steps, one or more of the processes, and/or one or more of theprocedures may also be performed in different orders, simultaneouslyand/or sequentially. In several exemplary embodiments, the steps,processes and/or procedures may be merged into one or more steps,processes and/or procedures. In several exemplary embodiments, one ormore of the operational steps in each embodiment may be omitted.Moreover, in some instances, some features of the present disclosure maybe employed without a corresponding use of the other features. Moreover,one or more of the above-described embodiments and/or variations may becombined in whole or in part with any one or more of the otherabove-described embodiments and/or variations.

Although several exemplary embodiments have been described in detailabove, the embodiments described are exemplary only and are notlimiting, and those skilled in the art will readily appreciate that manyother modifications, changes and/or substitutions are possible in theexemplary embodiments without materially departing from the novelteachings and advantages of the present disclosure. Accordingly, allsuch modifications, changes and/or substitutions are intended to beincluded within the scope of this disclosure as defined in the followingclaims. In the claims, any means-plus-function clauses are intended tocover the structures described herein as performing the recited functionand not only structural equivalents, but also equivalent structures.

What is claimed is:
 1. A system, comprising: an equipment unit; and anequipment base providing a load-bearing support for the equipment unit,the equipment base comprising: a first part, comprising: a firstsubstrate; a first elastomer disposed onto the first substrate; and afirst planar portion; a second part configured to be positioned adjacentto the first part, the second part comprising: a second substrate; asecond elastomer disposed onto the second substrate; and a second planarportion; wherein the first and second planar portions are coplanar whenthe second part is positioned adjacent to the first part; and anexpansion joint formed between the first and second parts to allow for afootprint of the equipment base to expand or contract due to movementcaused by the equipment unit.
 2. The system of claim 1, wherein thefirst and second parts are encapsulated by the first and secondelastomer, respectively, to provide the first part and the second part.3. The system of claim 2, wherein the first and second parts each havean R-Value, measured in accordance with ASTM C518, of about 2°F.ft²h/Btu to about 10° F.ft²h/Btu.
 4. The system of claim 2, whereinthe first part and the second part are shaped so that the expansionjoint is interlocking.
 5. The system of claim 2, wherein the equipmentbase further comprises a strap extending around an outer periphery ofthe equipment base to hold the first and second parts together.
 6. Thesystem of claim 1, wherein: the first and second parts comprise firstand second edges, respectively; and the second edge interfits with thefirst edge to at least partially form the expansion joint.
 7. The systemof claim 1, wherein the first and second substrates comprise foammaterial.
 8. The system of claim 7, wherein the foam material has adensity of at least 1 pound per cubic foot.
 9. The system of claim 7,wherein the foam material comprises expanded polystyrene.
 10. The systemof claim 1, wherein the first elastomer and the second elastomercomprise polyurea elastomer.
 11. The system of claim 1, wherein theequipment base is configured to distribute vibrational forces producedby the equipment unit to provide vibration dampening.
 12. The system ofclaim 1, wherein the equipment unit is selected from the groupconsisting of a heat exchanger, a compressor, a pump, a mixing vessel,an engine, and combination(s) thereof.
 13. A system, comprising: anequipment base comprising: a first part, comprising: a first substratehaving a first thickness; a first elastomer disposed onto the firstsubstrate; a first planar portion; and a first recess; a second partconfigured to be positioned adjacent to the first part, the second partcomprising: a second substrate having a second thickness; a secondelastomer disposed onto the second substrate; a second planar portion;and a second recess; wherein the first and second planar portions arecoplanar when the second part is positioned adjacent to the first partand perpendicular to each of the respective first and second thicknessesof the first and second parts; a key member configured to fit within thefirst and second recesses to adjoin the first part to the second part;and a seam formed between an outer circumference of the key member andthe first and second parts; and an equipment unit disposed on top of theequipment base, the equipment unit comprising a heat exchanger, acompressor, a pump, a mixing vessel, an engine, or combination(s)thereof.
 14. The system of claim 13, wherein the key member comprises athird substrate having a third thickness sized to provide load-bearingsupport for the equipment and a third elastomer disposed onto the thirdsubstrate.
 15. The system of claim 13, wherein the first substrate,second substrate, and third substrate comprise foam material.
 16. Thesystem of claim 13, wherein the first elastomer, the second elastomer,and the third elastomer comprise polyurea elastomer.
 17. A system,comprising: an equipment unit; and an equipment base disposed on asurface, the equipment base providing load-bearing support for theequipment unit and configured to allow fluid to pass from the equipmentunit and to the surface, the equipment base comprising: a first part,comprising: a first foam substrate having a first thickness; a firstelastomer coated onto the first foam substrate; a first planar portion;and a first recess; a second part configured to be positioned adjacentto the first part, the second part comprising: a second foam substratehaving a second thickness; a second elastomer coated onto the secondfoam substrate; a second planar portion; and a second recess; whereinthe first and second planar portions are coplanar when the second partis positioned adjacent to the first part and perpendicular to each ofthe respective first and second thicknesses of the first and secondparts; a key member configured to fit within the first and secondrecesses to adjoin the first part to the second part, wherein the keymember comprises a third foam substrate having a third thickness and athird elastomer disposed onto the third foam substrate; and an expansionjoint formed between the key member and the first and second parts toallow for a footprint of the equipment base to expand or contract due toexpansion or contraction, respectively, of the equipment base.
 18. Thesystem of claim 17, wherein the equipment unit comprises a heatexchanger, a compressor, a pump, a mixing vessel, an engine, orcombination(s) thereof.
 19. The system of claim 17, wherein theequipment unit comprises a storage tank.
 20. The system of claim 17,wherein: the substrate comprises a polystyrene foam; the first, second,and third elastomers comprise polyurea elastomer; and the equipment baseis configured to distribute vibrational forces produced by the equipmentunit. Page 15 of 16